Treadbelts Comprising a Specialized Surface, Treadmills Including Such Treadbelts, and Related Methods

ABSTRACT

A treadbelt for a treadmill may comprise a major surface comprising a plurality of tufts extending therethrough. The treadbelt may further comprise a first textile layer and a plurality of fibers extending through the first textile layer to provide the plurality of tufts. Additionally, the plurality of fibers may be sized, shaped and positioned to exhibit the appearance of turf. An additional treadbelt may comprise a major surface comprising a plurality of protrusions extending therefrom. The plurality of protrusions may be spatially distributed on the major surface of the treadbelt in an irregular and non-repeating configuration and may comprise irregular and non-repeating shapes. In some embodiments, a treadbelt may comprise a major surface configured to approximate to a runner the impact response of at least one of turf, sand, a trail, a ground vulcanized rubber track, and a hardwood surface.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application No. 61/625,847 filed Apr. 18, 2012.

TECHNICAL FIELD

In general, the present disclosure relates to exercise devices and components for exercise devices. More specifically, the present disclosure relates to treadbelts for treadmills that include a specialized surface, treadmills including such treadbelts, and related methods.

BACKGROUND

Conventional treadmills may include a treadbelt with a relatively flat surface that is compatible with running shoes. Such treadbelts may be effective for exercise and may provide a relatively comfortable surface for users. Such treadbelts, however, do not provide users with the feel and response of various common running surfaces. A treadbelt available to a football player would be no different than a treadbelt for a track runner, or for a beach volleyball player. Accordingly, if an athlete is not able to train on their actual field or environment, they are not currently able to approximate the running conditions of their sport on a treadmill. Additionally, conventional treadmills are not configured for footwear other than running shoes.

Similarly, conventional treadmills are also not specialized for barefoot running Barefoot running has become increasingly popular for runners, as it is believed that running without traditional running shoes may improve a runner's form, may reduce foot and leg injury, and may make running more enjoyable. Accordingly, many runners now run without shoes, or with shoes that have very thin soles with little to no cushioning. Consequently, these runners now tactilely experience the terrain beneath their feet. A barefoot runner using a traditional treadmill with a continuous, smooth, unchanging surface will not have the same tactile experience as they will have when running outside.

One type of treadmill belt is disclosed in U.S. Pat. No. 8,096,925 issued to Peter E. Radding et al. and assigned to Veyance Technologies, Inc. In this patent, a treadmill belt is disclosed that includes a fabric base and a foamed cushion layer. However, only a traditional outer wear layer is disclosed.

SUMMARY

In one aspect of the disclosure, a treadbelt for a treadmill may include a major surface having a plurality of tufts extending therethrough.

Another aspect of the disclosure may include any combination of the above-mentioned features and may further include a first textile layer and a plurality of fibers extending through the first textile layer to provide the plurality of tufts.

Another aspect of the disclosure may include any combination of the above-mentioned features and may further include a plurality of fibers that are sized, shaped and positioned to exhibit the appearance of turf.

Another aspect of the disclosure may include any combination of the above-mentioned features and may further include fibers having a cross-sectional shape exhibiting a breadth that is greater than a width thereof.

Another aspect of the disclosure may include any combination of the above-mentioned features and may further include fibers having a cross-section sized and shaped generally as a cross-section of a blade of grass.

Another aspect of the disclosure may include any combination of the above-mentioned features and may further include fibers having a generally circular cross-sectional shape.

Another aspect of the disclosure may include any combination of the above-mentioned features and may further include polymer fibers.

Another aspect of the disclosure may include any combination of the above-mentioned features and may further include at least one of polyamide fibers and polytetrafluoroethylene (PTFE) fibers.

Another aspect of the disclosure may include any combination of the above-mentioned features and may further include a plurality of fibers that extend over a portion of a first side of the first textile layer and the free ends of each of the plurality of fibers extending from an opposing second side of the first textile layer.

Another aspect of the disclosure may include any combination of the above-mentioned features and may further include a first textile layer including a woven textile layer.

Another aspect of the disclosure may include any combination of the above-mentioned features and may further include a second textile layer adhered to the first side of the first textile layer and extending over the middle portion of each of the plurality of fibers.

Another aspect of the disclosure may include any combination of the above-mentioned features and may further include the first textile layer having polyester yarns.

Another aspect of the disclosure may include any combination of the above-mentioned features and may further include fibers extending substantially straight from the second side of the first textile layer.

Another aspect of the disclosure may include any combination of the above-mentioned features and may further include fibers extending in a generally helical shape from the second side of the first textile layer.

Another aspect of the disclosure may include any combination of the above-mentioned features and may further include a major surface comprising a plurality of protrusions extending therefrom.

Another aspect of the disclosure may include any combination of the above-mentioned features and may further include a plurality of protrusions spatially distributed on the major surface of the treadbelt in an irregular and non-repeating configuration.

Another aspect of the disclosure may include any combination of the above-mentioned features and may further include the plurality of protrusions exhibiting irregular and non-repeating shapes.

Another aspect of the disclosure may include any combination of the above-mentioned features and may further include the appearance of naturally occurring rock shapes.

Another aspect of the disclosure may include any combination of the above-mentioned features and may further include a major surface configured to approximate to a runner the impact response of at least one of turf, sand, a trail, a ground vulcanized rubber track, and a hardwood surface.

Another aspect of the disclosure may include any combination of the above-mentioned features and may further include a major surface configured to approximate to a runner the visual appearance of at least one of turf, sand, a trail, a ground vulcanized rubber track surface, and a hardwood surface.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate various embodiments of the present method and system and are a part of the specification. The illustrated embodiments are merely examples of the present system and method and do not limit the scope thereof.

FIG. 1 illustrates a perspective view of a treadmill including a treadbelt having tufts extending therefrom according to an embodiment of the present disclosure.

FIG. 2 illustrates a plan view of an interior of a base portion of the treadmill of FIG. 1, according to one embodiment.

FIG. 3 illustrates a side view of the treadbelt of FIG. 1, according to one embodiment.

FIG. 4 illustrates a cross-sectional detail view of a portion of the treadbelt of FIG. 1, according to one embodiment.

FIGS. 5-9 illustrate cross-sectional views of fibers of a treadbelt, such as shown in FIG. 1, according to various embodiments.

FIG. 10 illustrates a plan view of an interior of a base portion of a treadmill, such as shown in FIG. 1, with a treadbelt having protrusions extending therefrom, according to another embodiment of the present disclosure.

FIG. 11 illustrates a cross-sectional detail view of a portion of the treadbelt of FIG. 10, according to one embodiment.

FIG. 12 illustrates a cross-sectional detail view of a portion of a treadbelt that approximates a sandy beach according to an embodiment of the present disclosure.

FIG. 13 illustrates a cross-sectional detail view of a portion of a treadbelt that approximates a track according to an embodiment of the present disclosure.

FIG. 14 illustrates a cross-sectional detail view of a portion of a treadbelt that approximates a hardwood floor according to an embodiment of the present disclosure.

Throughout the drawings, identical reference numbers designate similar, but not necessarily identical, elements.

DETAILED DESCRIPTION

The present disclosure provides a treadbelt for a treadmill that includes a specialized surface, such as a tufted surface and/or a surface having similarities to a natural surface. Such a specialized surface on a treadbelt may provide the user with a feel and response similar to a specific running surface, such as turf, a mountain trail, or another running surface, which may facilitate training for specific running conditions and sports.

Unless specified or limited otherwise, the terms “connected” and “associated with” are used broadly and encompass both direct and indirect connections and associations. Further, these terms are not restricted to mechanical attachments, but also include frictional, adhesive, magnetic and other attachments.

A treadmill including a treadbelt according to an embodiment of the present disclosure is illustrated in FIG. 1. As illustrated, a treadmill 10 may include a frame 12, a treadbelt 14 and a deck 16. The frame 12 may include various parts of the treadmill 10 and may impart structural stability and/or support to the treadmill 10. When installed on the treadmill, the treadbelt 14 is exposed at an upper region of the deck 16, and provides a movable surface upon which a user may walk and/or run. The treadmill 10 may additionally include a drive motor 18 associated with the treadbelt 14, positioned and configured to drive the treadbelt 14, as shown in FIG. 2. For example, the drive motor 18 may be connected to a roller 20 with a belt 22 and the treadbelt 14 may be positioned over the roller 20.

In some embodiments, such as shown in FIG. 3, the treadbelt 14 may include a major surface 24 comprising a plurality of tufts 26 extending therefrom. A plurality of fibers 28, 30 may extend from the surface 24 of the treadbelt 14 to form the tufts 26, and the plurality of fibers 28, 30 may be sized, shaped and positioned to exhibit the appearance of turf. Additionally, the plurality of tufts 26 may provide a surface 24 on the treadbelt 14 that exhibits a feel and/or an impact response similar to turf. The treadbelt 14 may include one or more textile layers 32, 34 and the plurality of fibers 28, 30 may extend through at least one textile layer 32 to provide the plurality of tufts 26 extending from the major surface 24 of the treadbelt 14.

As illustrated in FIG. 4, the treadbelt 14 may include a first textile layer 32 and a second textile layer 34 and, optionally, additional layers. The first textile layer 32 may include a woven textile comprising weft yarns interwoven with warp yarns, which may extend perpendicular to the weft yarns. The yarns of the first textile layer 32 may be made of a synthetic material, such as a polymer (e.g., polyester). The fibers 28, 30 may be threaded between and around yarns of the first textile layer 32. A middle portion 36 of each of the plurality of fibers 28, 30 may extend over a portion of a first side 38 of the first textile layer 32 and the free ends 40 of each of the plurality of fibers 28, 30 may extend from an opposing second side 42 of the first textile layer 32. In some embodiments, the middle portion 36 of the fibers 28, 30 may extend around warp yarns of the first textile layer 32. In further embodiments, the middle portion 36 of the fibers 28, 30 may extend around the weft yarns of the first textile layer 32. In yet further embodiments, the middle portion 36 of the fibers 28, 30 may extend around both the warp and weft yarns of the first textile layer 32.

A second textile layer 34 may be adhered to the first side 38 of the first textile layer 32 and may extend over the middle portion 36 of the fibers 28, 30. The second textile layer 34 may be also be comprised of a woven textile. The second textile layer 34, and an adhesive 44 between the first and second textile layers 32, 34 may hold the fibers 28, 30 in place and prevent the fibers 28, 30 from pulling out of the first textile layer 32 during normal operation of the treadmill 10. The second textile layer 34 may also form a second major surface of the treadbelt 14 (i.e., an inner surface of the treadbelt). Accordingly, the second textile layer 34 of the treadbelt 14 may contact the rollers 20 and the deck 16 of the treadmill 10 when installed thereon and may provide a relatively low friction interface between the deck 16 of the treadmill 10 and the treadbelt 14. Additional material layers may also be positioned adjacent to the second textile layer 34 to provide the interface between the deck 16 of the treadmill 10 and the treadbelt 14.

As illustrated in FIG. 4, a cushioning layer 46 may be positioned over the second side 42 of the first textile layer 32 and the fibers 28, 30 may extend through the cushioning layer 46. For example, the cushioning layer 46 may include one or more of a polymer material, a polymer foam, and a non-woven textile. The cushioning layer 46, combined with the tufts 26, may be selected to provide an impact response (i.e., foot-feel) approximating turf.

The fibers 28, 30 may have one or more cross-sectional shapes, which may affect the look and/or feel of the fibers 28, 30 (e.g., giving the fibers 28, 30 the look and/or feel of blades of grass). In some embodiments, the plurality of fibers 28, 30 may include fibers 28, 30 having a cross-sectional shape exhibiting a breadth that is greater than a width thereof, as shown in FIGS. 5-8, similar to a blade of grass. For example, fibers 28, 30 may have a cross-section shaped generally as a rectangle, as shown in FIG. 5, or a rounded rectangle, as shown in FIG. 6. For another example, fibers 28, 30 may have a cross-section shaped generally as a chevron, as shown in FIG. 7. For yet another example, fibers 28, 30 may have an arcuate cross-sectional shape, as shown in FIG. 8. For yet a further example, fibers 28, 30 may have a circular cross-sectional shape, as shown in FIG. 9.

Returning again to FIG. 4, the plurality of fibers 28, 30 that form the tufts 26 may include fibers 28 that extend substantially straight in a relaxed state (i.e., straight fibers) and may, include fibers 30 that extend in a generally helical shape (i.e., curly fibers). The straight fibers 28 may extend beyond the curly fibers 30 and visibly appear as blades of grass. The curly fibers 30 may be somewhat obscured from view by the straight fibers 28, but may provide structure to keep the straight fibers 28 extended substantially perpendicular to the surface of the treadbelt and reduce matting of the fibers 28. Additionally, the curly fibers 30 may provide resilience to the tufts 26 and provide a cushioning effect to a user running on the treadmill 10. The fibers 28, 30 may be comprised of a synthetic material, such as a polymer. For example, the plurality of fibers 28, 30 may include at least one of polymer fibers, polyamide fibers, and polytetrafluoroethylene (PTFE) fibers.

In Further embodiments, a treadbelt may include another specialized surface. For example, as shown in FIG. 10, a treadbelt 50 for a treadmill may include a major surface 52 having protrusions 54 extending therefrom. The protrusions 54 may be spatially distributed on the major surface 52 of the treadbelt 50 in an irregular and non-repeating configuration, so as to approximate the look and/or feel of a trail, or another natural footpath. The protrusions 54 may include irregular and non-repeating shapes. For example, the protrusions 54 may exhibit the appearance of naturally occurring rock shapes. As shown in FIG. 11, the treadbelt may include at least one textile layer 56, 58, a texture layer 60, and, optionally, a cushion layer 62. A first textile layer 56 may be a woven textile that may provide structural strength (e.g., tensile strength) to the treadbelt 50. Accordingly, the first textile layer 56 may be formed, at least in part, of high strength synthetic yarns, such as polymer yarns (e.g., polyester yarns). In one embodiment, a second textile layer 58 may be adhered to a first side 64 of the first textile layer 56, such as with an adhesive material, and the second textile layer 58 may provide an exterior surface of the interior of the treadbelt 50. Accordingly, the second textile layer 58 may provide a relatively low friction interface between the treadbelt 50 and a deck of a treadmill. The texture layer 60 may be formed from a relatively hard polymer material and may include the plurality of protrusions 54 molded or otherwise formed thereon. The optional cushion layer 62 may be positioned over a second side 66 (opposing the first side) of the first textile layer 56, between the first textile layer 56 and the texture layer 60. The cushion layer 62 may be adhered to the second side of the first textile layer 56 by an adhesive, or may include a polymer that is applied to the first textile layer 56 in a less than fully cured state and cured on the first textile layer 56. For example, the cushion layer 62 may include a foamed polymer. As an additional example, the cushion layer 62 may include at least one of a polymer material, polymer foam, and a non-woven textile. The cushion layer 62 can also be configured to approximate the impact response of a trail. Accordingly, the cushion layer 62 may provide an impact response similar to compacted soil.

In some embodiments, such as shown in FIG. 12, a treadbelt 70 may approximate the look and/or feel of a sandy beach. The treadbelt 70 may include an impact response similar to wet or dry packed sand and may have a textured surface 72 approximating the feel of sand. The treadbelt 70 may include at least one textile layer 74, 76, a cushion layer 78, and a texture layer 80. A first textile layer 74 may be a woven textile that may provide structural strength (e.g., tensile strength) to the treadbelt 70. Accordingly, the first textile layer 74 may be comprised of high strength synthetic yarns, such as polymer yarns (e.g., polyester yarns). Optionally, a second textile layer 76 may be adhered to a first side of the first textile layer 74, such as with an adhesive material, and the second textile layer 76 may provide an exterior surface of the interior of the treadbelt 70. Accordingly, the second textile layer 76 may provide a relatively low friction interface between the treadbelt 70 and a deck of a treadmill. The cushion layer 78 may be positioned over a second side of the first textile layer 74. The cushion layer 78 may be adhered to the second side of the first textile layer 74 by an adhesive, mechanical fasteners, or may comprised of a polymer that is applied to the first textile layer 74 in a less than fully cured state and cured on the first textile layer 74. For example, the cushion layer 78 may include a foamed polymer. As an additional example, the cushion layer 78 may include at least one of a polymer material, polymer foam, and a non-woven textile.

The texture layer 80 may be positioned over the cushion layer 78 and may provide the exterior of the outer surface of the treadbelt 70 and may provide an interface between the treadbelt 70 and a user and may approximate the texture of sand. Rather than actual sand forming the surface 72 of the treadbelt 70, the texture layer 80 may include a texture formed from a polymer, which may be less abrasive than sand. For example a polymer material may be applied to the surface of a treadbelt 70 utilizing a sputtering process that may provide a textured surface on the treadbelt 70. In further embodiments, sand may be utilized for texture, but not exposed on the surface 72 of the treadbelt 70. For example, sand may be mixed into a polymer and applied to a major surface of the treadbelt 70, or a polymer layer may be formed over a layer of sand to provide a similar feel to sand without the same abrasive properties of sand. In view of the foregoing, the texture layer 80 and the cushion layer 78 may approximate the impact response of sand (e.g., packed sand). Such embodiments may approximate the sensation and impact response of running on a beach, especially for barefoot runners.

In addition to providing specialized surfaces that approximate natural surfaces, some embodiments may provide a specialized surface that emulates a manmade surface. In some embodiments, a ground vulcanized rubber 82 may be applied to a major surface 84 of a treadbelt 86 to provide a specialized surface that approximates a track surface, as shown in FIG. 13. In additional embodiments, such as shown in FIG. 14, a polymer with a relatively high hardness may be applied to a major surface 92 of a treadbelt 94 to approximate a hardwood surface (e.g., a basketball court). For example, a polymer layer 96 having a durometer hardness between about 80 Shore D and about 90 Shore D may be applied to the major surface 92 of the treadbelt 94. The specialized surface of the treadbelt 94 may additionally have a surface roughness similar to a finished hardwood floor.

INDUSTRIAL APPLICABILITY

Currently, it is not possible for many athletes to approximate the running conditions of their sport on a treadmill. Conventional treadmills may include a treadbelt with a relatively flat surface that is compatible with running shoes, but that may not be compatible with other shoes, such as cleats. Accordingly, such treadbelts do not provide users with the feel and response of various common running surfaces. A treadbelt available to a football player would be no different than a treadbelt for a track runner, or for a beach volleyball player.

Furthermore, conventional treadmills are also not specialized for barefoot running Accordingly, a barefoot runner using a current treadmill may not have the same tactile experience as they may have when running outside, as the treadbelts have a continuous, smooth, unchanging surface.

The present disclosure provides treadbelts for treadmills that include a specialized surface, such as a tufted surface and/or a surface having similarities to a natural surface. Such a specialized surface on a treadbelt may provide the user with a feel and response similar to a specific running surface, such as turf, a mountain trail, or another running surface, which may facilitate training for specific running conditions and sports.

In some embodiments, a treadbelt may include tufts extending from a major surface. The tufts may be comprised of a plurality of fibers that are sized, shaped and positioned to exhibit the appearance of turf. Additionally, the tufts may provide a surface that exhibits a feel similar to turf.

In further embodiments, a treadbelt may include a major surface comprising protrusions spatially distributed on the major surface of the treadbelt in an irregular and non-repeating configuration. Such embodiments may approximate the look and/or feel of a trail or another natural footpath.

In additional embodiments, a treadbelt may approximate the look and/or feel of a sandy beach, may exhibit an impact response similar to wet or dry packed sand, and may have a textured surface approximating the feel of sand.

In addition to providing specialized surfaces that approximate natural surfaces, some embodiments may provide a specialized surface that emulates a manmade surface or a hardwood surface (e.g., a basketball court).

In view of the foregoing, a user may select a treadbelt with a specialized surface for a specific training or exercise. For example, an athlete that competes on turf, such as a football player, may train on a treadmill with a treadbelt having a surface that approximates turf. Additionally, the athlete may run using footwear worn in competition, such as cleats, on the specialized surface. This may allow the user to better train for competition, and may facilitate the evaluation of footwear for competition. As another example, an athlete that competes on the sand, such as a beach volleyball player, may train on a treadmill having a treadbelt approximating the impact response and feel of sand.

Treadmills comprising treadbelts with specialized surfaces may also provide a superior running experience to runners with preferences for particular running surfaces, especially barefoot runners. 

What is claimed is:
 1. A treadbelt for a treadmill, the treadbelt comprising a major surface, wherein said major surface includes a top surface and a plurality of tufts extending through said top surface.
 2. The treadbelt of claim 1, further comprising: a first textile layer having a first side and an opposing second side, wherein said first side defines said top surface; and a plurality of fibers extending through the first textile layer to provide the plurality of tufts.
 3. The treadbelt of claim 2, wherein the plurality of fibers are sized, shaped and positioned to exhibit the appearance of turf.
 4. The treadbelt of claim 3, wherein the plurality of fibers comprise fibers having a cross-sectional shape exhibiting a breadth that is greater than a width thereof.
 5. The treadbelt of claim 4, wherein the plurality of fibers comprise fibers having a cross-section sized and shaped generally as a cross-section of a blade of grass.
 6. The treadbelt of claim 3, wherein the plurality of fibers comprise fibers having a generally circular cross-sectional shape.
 7. The treadbelt of claim 2, wherein the plurality of fibers comprise polymer fibers.
 8. The treadbelt of claim 7, wherein the plurality of fibers comprise at least one of polyamide fibers and polytetrafluoroethylene fibers.
 9. The treadbelt of claim 2, wherein a middle portion of each of the plurality of fibers extends over a portion of said second side of the first textile layer and the free ends of each of the plurality of fibers extend from said first side of the first textile layer.
 10. The treadbelt of claim 9, wherein the first textile layer comprises a woven textile layer.
 11. The treadbelt of claim 9, further comprising a second textile layer adhered to the second side of the first textile layer and extending over the middle portion of each of the plurality of fibers.
 12. The treadbelt of claim 9, wherein the first textile layer comprises a polyester yarn.
 13. The treadbelt of claim 9, wherein the plurality of fibers comprise fibers extending substantially straight from the first side of the first textile layer.
 14. The treadbelt of claim 13, wherein the plurality of fibers further comprise fibers extending in a generally helical shape from the first side of the first textile layer.
 15. A treadbelt for a treadmill, the treadbelt comprising a major surface, wherein said major surface includes a top surface and a plurality of protrusions extending from said top surface.
 16. The treadbelt of claim 15, wherein the plurality of protrusions are spatially distributed on the major surface of the treadbelt in an irregular and non-repeating configuration.
 17. The treadbelt of claim 16, wherein the plurality of protrusions comprise irregular and non-repeating shapes.
 18. The treadbelt of claim 16, wherein the plurality of protrusions exhibit the appearance of naturally occurring rock shapes.
 19. A treadbelt for a treadmill, the treadbelt comprising a major surface configured to approximate to a runner the impact response of at least one of turf, sand, a trail, a ground vulcanized rubber track, and a hardwood surface.
 20. The treadbelt of claim 19, wherein the major surface configured to approximate to a runner the visual appearance of at least one of turf, sand, a trail, a ground vulcanized rubber track surface, and a hardwood surface. 